Article for providing protection to an appendage from infectious agents and method of manufacturing same

ABSTRACT

The subject application includes a disposable foot cover that has a body, an open edge, a retention mechanism, and a tab. The body is roughly in the shape of a foot and is made of a compound that has rubber-like properties and is configured to provide a barrier against infectious agents. The open edge is located at one end of the body and is configured to receive an associated foot. The retention mechanisms, located around the open edge, are adapted for securing the cover to the associated foot. In addition, the tab, located at the rear of the opening, is suitably configured to enable removal of the cover from the associated foot.

CROSS REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation-in-part and contains subjectmatter claiming benefit of the priority date of U.S. Des. Pat. App. Ser.No. 29/464,933 filed on Aug. 22, 2013, which in turn claims the benefitof priority from U.S. patent application Ser. No, 13/314,141 filed onDec. 7, 2011, now abandoned, which claims the benefit of priority fromU.S. Provisional Pat. App. Ser. No. 61/459,163 filed Dec. 8, 2010, theentire contents of which are incorporated by reference herein,

BACKGROUND OF THE INVENTION

1. Field of Invention

The subject application is directed generally to protective wearingapparel. The application is particularly suited to providing a barrierbetween an appendage, such as a foot, and various microorganisms, i.e.infectious agents.

2. Background of Invention

Each day, an individual comes into contact with multiple sources ofinfection. A person will generally wash or disinfect his or her hands ona regular basis. However, the hands are not the only unprotected portionof the body that can contact various sources of infections. At airports,hotel rooms, some ethnic restaurants, gyms, health clubs, etc., anindividual may have to remove shoes, socks, hose, or the like, allowingtheir feet to contact sources of athlete's foot, fungal diseases,bacterial diseases, and viral diseases. With regard to airportsspecifically, a person is at risk simply by walking barefoot in the sameplace as any of the thousands of people who may have previously stoodthere and had any of the myriad of bacterial and viral diseases. Samplestaken using Petri dishes at such airports as Lindbergh Field in SanDiego, McCann Airport in Las Vegas and Sky Harbor Airport in Phoenixshowed fungus, mold and bacteria. It is very distasteful for many peopleto walk barefoot on the carpet in a hotel room that has been visited bya multitude of people. This also puts a person at risk for bacterial andviral diseases. Additionally, standing on the shower floor also lendsitself to such diseases. This also applies to the showers in healthclubs and gyms, Current items for use in shower include flip flops,which are not disposable, by nature, and thus retain mold, mildew,bacteria, fungi, and the like. Furthermore, the user of flip flops mustfirst wipe them off before placing them back in their gym bag or luggageor they will be taking the bacteria home with them.

SUMMARY OF THE INVENTION

In accordance with one embodiment of the subject application, there isprovided a system, method and article of manufacture for protecting feetfrom contaminants.

According to one embodiment of the subject application, there isprovided a system, method and article of manufacture for providing abarrier between a foot and a biological contaminant, including diseasecausing bacteria and viruses.

Further, in accordance with one embodiment of the subject application,there is provided a system, method and article of manufacture for easingthe sanitary concerns of patrons of at least airports, gyms, hotels,clubs, stores, and the like.

Still further in accordance with one embodiment of the subjectapplication, there is provided a disposable foot cover comprised of asuitable barrier material that is capable of conforming to the foot of auser. The foot cover is preferably manufactured of a material thatprovides viral and bacterial protection, and which is abrasion andpuncture resistant. The foot cover further includes a suitable retentionmechanism so as to secure the foot cover on the foot of a user. Suitableretention mechanisms include, for example and without limitation,elastic, hook and latch, button, snap, and the like.

In yet another embodiment of the subject application, the disposablefoot cover may have perforations or other suitable openings along theupper surface of the foot cover associated with the top of a wearer'sfoot to promote air flow and breathability of the foot cover therebyincreasing the comfort of the wearer while wearing the foot cover.

Still further in accordance with an alternative embodiment of thesubject application, the disposable foot cover may be comprised of asuitable barrier material further comprising a flocked inside surface toprovide a soft surface of contact with a wearer's foot.

In yet a further embodiment of the subject application, the disposablefoot cover may include ridges and/or a suitable texture on the bottomsurface of the foot cover to promote traction and prevent slipping onsmooth surfaces such as wooden and tiles floors.

Still other advantages, aspects, and features of the subject applicationwill become readily apparent to those skilled in the art from thefollowing description, wherein there is shown and described a preferredembodiment of the subject application, simply by way of illustration ofone of the modes best suited to carry out the subject application. As itwill be realized, the subject application is capable of other differentembodiments, and its several details are capable of modifications invarious obvious aspects, all without departing from the scope of thesubject application. Accordingly, the drawings and descriptions will beregarded as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The present application may be more fully appreciated in connection withthe following detailed description taken in conjunction with theaccompanying drawings.

FIG. 1 shows a side view of a disposable foot cover in accordance withat least one preferred embodiment of the present invention.

FIG. 2 is an opposite side view of the disposable foot cover shown inFIG. 1.

FIG. 3 is a top view of the disposable foot cover shown in FIG. 1.

FIG. 4 is a bottom view of the disposable foot cover shown in FIG. 1.

FIG. 5 is a rear view of the disposable foot cover shown in FIG. 1.

FIG. 6 is a front view of the disposable foot cover shown in FIG. 1,

FIG. 7 shows a perspective view of a disposable foot cover in accordancewith a preferred embodiment of the present invention.

FIG. 8A shows a short anklet-type embodiment and FIG. 8B shows anextended sock-type embodiment of the present invention.

FIG. 9 shows a side view of a disposable foot cover with a texture, tiestring retention mechanism, and a removal tab in accordance with anotherpreferred embodiment of the present invention.

FIG. 10 shows a side view of another disposable foot cover with atexture, flap and snap retention mechanism, and a removal elongated tabmember in accordance with another preferred embodiment of the presentinvention.

FIG. 11 is a side view of a disposable foot cover casting mold used in amanufacturing process in accordance with a preferred embodiment of thepresent invention.

FIG. 12 is a side view of another disposable foot cover casting moldused in a manufacturing process in accordance with a preferredembodiment of the present invention.

FIG. 13 is a side view of a disposable foot cover dipping mold used in amanufacturing process in accordance with a preferred embodiment of thepresent invention.

FIG. 14 is a side view of another disposable that cover dipping moldused in a manufacturing process in accordance with a preferredembodiment of the present invention.

FIG. 15 is a flow chart which depicts a preferred manufacturing processfor producing disposable foot covers in accordance with at least oneembodiment of the present invention.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

The present invention is directed to a system, method, and article ofmanufacture for protecting feet. In particular, the present invention isdirected to a disposable foot cover (also called protective footapparel). The foot cover may be composed of a suitable biologicallyimpermeable layer, such as nitrile butadiene rubber (trade names Nipol®,Krynac®, and Europrene®), latex, or other such material, as discussed ingreater detail below. The disposable foot cover/liner/bootie facilitatesthe protection of feet from various foot infections such as athlete'sfoot, fungal toenails, bacterial and viral diseases to which patrons areexposed when they are expected to remove their shoes in variouscircumstances. The disposable foot covers are capable of being worn oversocks or on bare feet prior to the addition of shoes in anticipation ofsuch occasions. In this manner, a user would he prepared in the eventthey would have to take their shoes off and prefer not to walk directlyon the floor in public places such as airports, hotels, gyms, healthclubs, ethnic restaurants and the like, Likewise, a health consciousentity requiring the removal of patron's shoes may provide protection tousers from the unavoidable contaminants covering a shared floor spaceusing an easy and cost effective approach.

Referring to FIGS. 1, 2, 3, 4, 5 and 6, in certain preferred embodimentsof the present invention, a disposable foot covering 1 may include abody 10, having a top 12, a heel 14, a toe 16, a side 18, and a bottom19. The sides 18 and top 12 define an open edge 13 (also referred to asan opening) proximate the top 12. In accordance with one exampleembodiment of the present invention, the body 10 may be form factored tofit snugly on a user's foot. As such, a heel 14 and a toe 16 portion maybe appropriately shaped to receive a user's foot, as shown in FIGS. 8 aand 8 b. One skilled in the art will appreciate that the foot coveringmay be produced in a plurality of shapes and sizes. In other embodimentsof the present invention, the open edge 13 of the foot covering 1 mayalso he produced in a plurality of shapes and sizes suitable to receivedifferent types of foot coverings (e.g., socks, shoes, sandals, etc.).In accordance with one example embodiment of the present invention, thebody 10 may be made of any suitable material or fabric. For example, thebody 10 material may comprise a synthetic rubber compound or abreathable fabric (e.g., nylon, cotton, etc.).

In certain preferred embodiments of the present invention, the body 10material may require an impermeable material to prevent contaminants(e.g., bacteria, viruses, dirt, etc.) outside the body 10 frompenetrating the interior of the foot cover 1. A typical material usedfor this particular embodiment may include a nitrile-type rubber. Aswill be appreciate by those skilled in the art, the flexibility andsoftness of nitrile-type rubbers makes them very comfortable andconforming, as demonstrated by the medical/surgical gloves of similarmaterials currently in use. In addition thereto, the nitrile-type rubberoffers dexterity and extended wear comfort.

The skilled artisan will appreciate that other materials may be capableof being employed in the manufacture of the disposable foot cover 1provided in the above example embodiment; however that such material ispuncture resistant and very durable. Preferably, this material willfarther have resistance to abrasion superior to that of natural lubber,provide a strong barrier of protection against infectious agents, andprevent the transmission of infectious agents, especially viruses.

The body 10 of the present invention may also be produced in a pluralityof thicknesses depending on the desired characteristics (e.g., fit,feel, aesthetics, etc.) of a particular embodiment. Thickness of thematerial of the body 10 may range from sheer, like pantyhose, toreinforced, like the rubber sole of a shoe. Moreover, the thickness ofthe body 10 material may vary throughout to achieve desiredcharacteristics of a particular embodiment. For example, a portion ofthe body 10 on top of a user's foot may be thin while the bottom 19 maybe thicker to provide foot and ankle support. For thicker embodiments ofthe foot cover, it is contemplated that the foot cover may includeperforations 30 or other suitable openings along the upper surface ofthe foot cover (FIGS. 8 a and 8 b) associated with the top of a wearer'sfoot to promote air flow and breathability of the foot cover therebyincreasing the comfort of the wearer while wearing the foot cover.

It will be appreciated by the skilled artisan that nitrile-type rubberis available in different grades and thicknesses. According to oneembodiment of the present invention, the disposable foot covers 1 may bemanufactured in the “high risk” category (i.e., the same grade as thegloves used by technicians, paramedics, and firemen in the emergencymedical fields). With respect to the thickness of this particularembodiment, a suitable range may be 0.05 to 0.07 mm in thickness of thewalls (such as the sides 18) of the cover 1 (i.e. “ultra-thin”nitrile-type rubber). The skilled artisan will appreciate that suchthickness allows for greater tactile sensation and can be made in avariety of sizes for both men and women. Furthermore, the “ultra-thin”nitrile also may enable the disposable foot covers 1 to fit snugly whenworn either over socks or on the bare foot.

Additionally, the body 10 material may be fused, covered, or otherwisecoupled with an antibacterial or antimicrobial agent to further protecta user from contamination. These substances may help to disinfect andinhibit the growth of infectious agents on the outside surface of thedisposable foot cover as well as the floor surface a user is walking on.

The body 10 of a disposable foot cover 1 may be produced in differentshapes and designs to accommodate a desired use for a particularembodiment. For example, an embodiment of the disposable foot covers maybe made specific to the foot on which they are to be worn (i.e. rightfoot, left foot). In another embodiment, the disposable foot covers 1may be ambidextrous. In accordance with another embodiment of thepresent invention, the foot covers may be configured with separatecompartments for individual toes or groups of toes, or may be configuredfor usage with sandals, flip-flops and the like, In another embodimentof the present invention the body 10 of the disposable foot covering maybe fitted to a universal one-size-fits-all template, as opposed to footshaped form factor shown in FIGS. 3 and 4.

In other embodiments the materials and body 10 surfaces may be producedwith various attributes. Preferably, the interior surface material usedin the manufacture of disposable foot covers of the present inventionmay be non-toxic and non-irritant so as to avoid causing skin allergies.In a further embodiment, the interior surface of the material mayinclude a flocked inside surface to provide a soft surface of contactwith a wearer's foot However, in other preferred embodiments of thepresent invention, the outside surface of the body 10 of the foot covermay have an apparent texture 126, 226 or design 128, 228 (see e.g.,FIGS. 9 and 10). The surface texture characteristics may vary dependingon the particular application and materials used, but may feel or look,for example, smooth (e.g., nylon, firm rubber compound), soft (e.g.,cotton), or possibly even rough (e.g., snakeskin, alligator scales). Itwill be appreciated by the skilled artisan that the surface texture maybe achieved during manufacturing of the foot cover according to theprocess known in the art as flocking.

Further, the bottom 19 of an embodiment of the present application maybe textured as well. The texture on the bottom 19 may be functional,such as a texture that provides traction, or may be aesthetic in nature.Generally, FIGS. 9 and 10 show a texture (126, 226 on the bottom 19;128, 228 on the side 18) on the outside surface of a disposable footcover in accordance with at least one embodiment of the invention.Furthermore, other embodiments may be manufactured in a plurality ofcolors. In one embodiment, the outside surface of the body 10 may becustomized for color, text, design, or other similar indicia, for acompany, airline, hotel, sports team, and the like. FIG. 9 shows texture128 for example which could represent a particular embodiment of thedesign mentioned above with a company logo visible on the side 18 of thefoot cover 1. FIG. 10 shows texture 226 for example which providessurface texture on the bottom 19 of the cover 1. The skilled artisanwill appreciate that various advertisements are also capable of beingincorporated on the disposable covers so as to offset the costsassociated therewith.

In another preferred embodiment of the present invention, a disposablefoot cover also may include a suitable retention mechanism (122, 222,and 322) so as to secure the cover on the foot of a user. Suitableretention mechanisms include, for example and without limitation,elastic 122 (e.g., as shown in FIG. 7), tie-string 222 (e.g., as shownin FIG. 9), flap 322 a and snap 322 b (e.g., as shown in FIG. 10), hookand latch, button, and the like. In accordance with one exampleembodiment of the present invention, FIG. 7 shows a disposable footcover with a body 10 comprised of a synthetic rubber compound andincludes an elastic retention mechanism 122 around the open edge 13 soas to allow ingress and egress of a foot, as well as to removably affixthe foot cover to the foot. Similarly, the open edge 13 may include anelastic ring retention mechanism (akin to 122 with added elastic ring)to more effectively maintain a grip around the ankle of a foot insertedtherein, as shown in FIGS. 7 and 8 a. In yet another embodiment, thematerial from which the body 10 of the disposable foot cover is madestretches to accommodate a foot, such that the cover is secured to thefoot by the elasticity of the material. Alternatively, the body 10 mayinclude an extended section of material proximate to top 12 such thatthe open edge 13 of the foot cover 1 extends above the ankle of thewearer when worn (see e.g., FIG. 8 b).

In another preferred embodiment of the present invention, a disposablefoot cover 1 also may include a removal tab 124, 224, located at therear of the open edge 13, suitably attached or formed as a part of thecover so as to enable a user to readily and easily remove the cover froma foot without touching the possibly contaminated body 10. The removaltab 124, 224 may be produced from any suitable material or fabric andmay be designed to satisfy any aesthetic or functional goals of aparticular embodiment. For example, FIG. 9 shows a foot cover embodimentwith a fabric loop removal tab 124, attached to the rear of the body 10above the heel 14 of the cover 1. FIG. 10 shows another foot coverembodiment with an elongated member removal tab 224, such as a smallrod, string, or the like, to facilitate easy removal of the cover by auser. The tab 124 of FIG. 9 or the elongated member 224 of FIG. 10 maythen be used to effectively dispose of the foot cover withoutcontaminating the user,

Attention is now drawn to FIG. 15 which depicts a preferredmanufacturing process for producing foot covers in accordance with atleast one embodiment of the present invention. The steps 31 to 36 of theprocess may include creating one or more template patterns of a footcover design, using the templates to produce silicone casts or castingmolds 40 (shown in FIGS. 11 and 12), fabricating urethane dipping molds50 from the silicone casts (shown in FIGS. 13 and 14) and coating thedipping molds with a coagulant, submerging the urethane molds in a latextank, baking the molds in an oven to vulcanize the latex (or othersuitable material), and, after sufficient heating at suitabletemperature for the material to cook, cure, harden and/or firm thematerial, stripping the cured latex from the dipping molds and coatingthe latex in talc or silicone to prevent sticking. Afterwards, thedipping molds 50 may be cleaned and reused in the production process(e.g., steps 33-36)

To summarize, in accordance with one example embodiment of the subjectapplication, the disposable foot covers are comprised of a syntheticrubber compound that includes elastic around the open edge so as toallow ingress and egress of a foot, as well as to removably affix thefoot cover to the foot. According to one particular embodiment of thesubject application, the disposable foot cover includes a tab, locatedat the rear edge of the opening, suitably attached or formed as a partof the cover so as to enable a user to readily and easily pull off thedisposable foot cover and not have to touch the used area.

The foot cover further includes a suitable retention mechanism so as tosecure the foot cover on the foot of a user. Suitable retentionmechanisms include, for example and without limitation, elastic, hookand latch, button, snap, and the like. According to one embodiment ofthe subject application, the opening includes an elastic ring so as tomaintain a grip around the ankle of a foot inserted therein. Inaccordance with another embodiment of the subject application, thematerial from which the cover is made stretches to accommodate a foot,such that the cover is secured to the foot by the elasticity of thematerial. In yet another embodiment of the subject application, theretention mechanism may be the result of the material extending abovethe ankle of the wearer thereby preventing the foot cover frominadvertently coming off the foot.

The skilled artisan will appreciate that other materials are capable ofbeing employed in the manufacture of the disposable foot cover provided,however that such material is puncture resistant and very durable.Preferably, this material will further have resistance to abrasionsuperior to that of natural rubber, provide a strong barrier ofprotection against infectious agents, and prevent the transmission ofinfectious agents, especially viruses.

According to one embodiment of the subject application, a plurality ofsizes is capable of being produced so as to ensure proper fit. As willbe appreciate by those skilled in the art, the flexibility and softnessof nitrite-type rubbers makes them very comfortable and conforming, asdemonstrated by the medical/surgical gloves of similar materialscurrently in use. In addition thereto, the nitrile-type rubber offersdexterity and extended wear comfort.

It will be appreciated by the skilled artisan that nitrile-type rubberis available in different grades and thicknesses. According to oneembodiment of the subject application, the disposable foot covers wouldbe manufactured in the “high risk” category, i.e. the same grade as thegloves used by technicians, paramedics, and firemen in the emergencymedical fields. With respect to the thickness of the disposable footcovers, a suitable range is 0.05 to 0.07 mm in thickness, i.e.“ultra-thin” nitrile-type rubber. The skilled artisan will appreciatethat such thickness allows for greater tactile sensation and can be madein a variety of sizes for both men and women. The “ultra-thin” nitriteenables the disposable foot covers to fit snugly when worn either oversocks or on the bare foot. In one embodiment, the foot covers are madespecific to the foot on which they are to be worn, i.e. right foot, leftfoot. In accordance with another embodiment of the subject application,the disposable foot covers are ambidextrous. According to a furtherembodiment of the subject application, the foot covers are configuredfor usage with sandals and flip-flops, as well as having separatecompartments for each individual toes or groups of toes.

Preferably, the material used in the manufacture of disposable footcovers of the subject application is non-toxic and non-irritant so as toavoid causing skin allergies. According to another embodiment of thesubject application, the disposable foot cover is capable of beingmanufactured in a plurality of colors. In one embodiment, the subjectapplication provides a customized option for color, text, or the like,for a company, airline, hotel, sports team, and the like. The skilledartisan will appreciate that various advertisements are also capable ofbeing incorporated on the disposable covers so as to offset the costsassociated therewith.

The foregoing description of a preferred embodiment of the presentinvention has been presented fin purposes of illustration anddescription. It is not intended to be exhaustive or to limit the presentinvention to the precise form disclosed. Obvious modifications orvariations are possible in light of the above teachings. The embodimentwas chosen and described to provide the best illustration of theprinciples of the present invention and its practical application tothereby enable one of ordinary Skill in the art to use the subjectapplication in various embodiments and with various modifications as aresuited to the particular use contemplated. All such modifications andvariations are within the scope of the present invention as determinedby the appended claims when interpreted in accordance with the breadthto which they are fairly, legally, and equitably entitled.

What is claimed:
 1. A disposable foot cover, comprising: a body roughlyin the shape of a foot having a top surface and a bottom surface; anopening located on the top surface of the body configured to receive anassociated foot therein and wherein the foot is completely enclosed bythe body; a retention mechanism located at the opening, adapted forsecuring the cover to the associated foot and preventing the body frominadvertently disassociating with said foot; and a removal tab locatedat the rear of the opening suitably configured to enable removal of thecover from the associated foot without requiring a wearer to come incontact with the bottom surface of the cover; wherein the foot cover ismade of a compound having rubber-like properties and configured toprovide a barrier against infectious agents.
 2. The disposable footcover of claim 1, further comprising a texture on the outside surface ofthe body.
 3. The disposable foot cover of claim 1, further comprising atexture on the inside surface of the body.
 4. The disposable foot coverof claim 3, wherein said texture is incorporated into the body by theprocess of flocking
 5. The disposable foot cover of claim 2, whereinsaid texture is in the form of ridges positioned on the bottom surfaceof the body to provide traction.
 6. The disposable foot cover of claim1, wherein the top surface of the body further includes perforations oropenings to provide breathability and comfort for the wearer.
 7. Thedisposable foot cover of claim 1, wherein said retention mechanism isselected from the group consisting of elastic, hook and latch, button,snap, and extended material at the opening of the body.
 8. Thedisposable foot cover of claim 7, wherein said retention mechanism isextended material at the opening of the body.
 10. The disposable footcover of claim 1, wherein said removal tab is selected from the groupconsisting of a loop of material, a rigid elongated member and anon-rigid elongated member.
 11. The disposable foot cover of claim 6,further comprising a texture on the outside surface of the body.
 12. Thedisposable foot cover of claim 6, further comprising a texture on theinside surface of the body.
 13. The disposable foot cover of claim 6,wherein said texture is incorporated into the body by the process offlocking
 14. The disposable foot cover of claim 6, wherein said textureis in the form of ridges positioned on the bottom surface of the body toprovide traction.
 15. The disposable foot cover of claim 6, wherein saidremoval tab is selected from the group consisting of a loop of material,a rigid elongated member and a non-rigid elongated member.
 16. Thedisposable foot cover of claim 7, wherein said removal tab is selectedfrom the group consisting of a loop of material, a rigid elongatedmember and a non-rigid elongated member.